- Backhoe Loader:
- 416C (PIN: 4ZN1-16043; 5YN1-15147; 1WR1-8115; 1XR1-2183)
Introduction
This special instruction outlines the basic steps in order to install a 135-7196 Auxiliary Lines Kit on a backhoe loader. The 135-7196 Auxiliary Lines Kit is specifically designed for the operation of hydraulic hammers.
Note: If your machine does not have a valve control for the seventh bank in the backhoe control valve bank, you must install either a 106-6373 Valve Control or a 112-1842 Valve Control . A valve control is needed in order to control any attachments which are connected to the auxiliary lines. See the section ""Installing a Valve Control" " in this publication for installation instructions.
The information in this instruction should be read and understood before you proceed with any modifications. Also refer to the Service Manual for the machine.
Required Tools
Required Parts     | ||
Quantity     | Part Number     | Description     |
1     | 1U-5236     | Welding Rod     |
1     | 1U-8168     | Drill Bit (1)     |
( 1 ) | The package contains five drill bits which can cut a hole to a diameter of 10 mm (0.4 inch). |
Preparing the Machine for Servicing
- Park the machine on a level surface.
- Apply the service brake in order to stop the machine. Move the transmission control lever to the NEUTRAL position.
- Move the speed control lever to the LOW IDLE position.
- Engage the parking brake.
- Engage the transmission neutral lock.
- Lower the loader assembly to the ground.
- Put the backhoe loader in the servicing position. The bucket must rest on the ground. Refer to Illustration 1.
Note: Support the weight of the boom, stick, and bucket. Use the correct jacks or supports. Total weight of the boom, stick, and bucket is approximately 1815 kg (4001 lb).
Illustration 1 | g00287246 |
Put the backhoe loader in the servicing position. |
- Stop the engine.
- Turn the engine start switch key to the OFF position. Remove the key.
- Move the hydraulic control levers back and forth in order to relieve the hydraulic pressure in the system.
Hydraulic oil pressure can remain in the hydraulic systems after the engine and pump have been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic systems. To prevent possible injury, refer to the section, Testing and Adjusting, "Hydraulic System Pressure - Release" before any fitting, hose or component is loosened, tightened, removed or adjusted. When possible, the bucket or attachment must always be lowered to the ground before service is started. When it is necessary for the boom to be in the raised position while tests or adjustments are done, be sure that the boom, stick and bucket or attachment have correct support. The swing lock (if equipped) must be engaged before service is started. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made. |
- Move the hydraulic control levers to the HOLD position.
Note: The pressure in the hydraulic system has now been released. Hydraulic lines and components can now be removed.
- Place chocks in front of the rear wheels and behind the rear wheels.
Gaining Access to the Hydraulic Lines
Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Release the hydraulic pressure. Refer to ""Preparing the Machine for Servicing" ".
- Remove the four bolts (B) which secure the floormat (A) to the floor of the cab. Refer to Illustration 2.
Illustration 2 | g00481684 |
(A) Floormat (B) Bolts (C) Rear console |
- Remove the rear console (C). Refer to Illustration 2.
- Remove the four bolts (D) which secure the floorplate (E) to the machine.
Illustration 3 | g00481700 |
(D) Bolts (E) Floorplate |
- Remove clips (G) and (H). Save the bolt 8T-4137 Bolt (J) and 8T-4121 Washer (K). The bolt and the washer will be used in the assembly procedures. Refer to Illustration 4.
Illustration 4 | g00482243 |
(G) Clip (H) Clip (J) 8T-4137 Bolt (K) 8T-4121 Washer (L) Hose (M) Seal (N) Connection (P) Hose |
- Remove the following parts: hydraulic line (L), seal (M) and connector (N). Refer to Illustration 4.
Note: Caps and plugs will prevent contamination from entering the hydraulic system. Use the caps and plugs on the following parts: all hydraulic lines, hoses and tubes.
- Remove hose (P). Remove any other hoses which are attached to hose (P) .
Installing a Valve Control
If your machine is not equipped with a valve control for the seventh bank in the main hydraulic control group, you must install either a 106-6373 Valve Control or a 112-1842 Valve Control . A valve control is necessary in order to operate any attachments which are connected to the auxiliary lines kit.
The 106-6373 Valve Control is operated by the operator's foot. The 112-1842 Valve Control is hand operated.
Required Parts
Parts in the 106-6373 Valve Control     | |||
Item     | Quantity     | Part Number     | Description     |
1     | 1     | 106-6374     | Support     |
2     | 2     | 8T-4195     | Bolt     |
3     | 4     | 8T-4121     | Hard Washer     |
4     | 4     | 8T-4133     | Nut     |
5     | 1     | 128-7341     | Shaft     |
6     | 2     | 9R-2614     | Bearing     |
7     | 1     | 109-0533     | Seal     |
8     | 1     | 121-0593     | Pedal Assembly     |
9     | 1     | 6V-8335     | Bolt     |
10     | 1     | 8T-4773     | Ball Joint     |
11     | 1     | 155-6011     | Rod     |
12     | 1     | 8T-4815     | Rod End     |
13     | 1     | 9R-2806     | Pin     |
14     | 1     | 9R-2807     | Clip     |
15     | 1     | 6V-7744     | Locknut     |
16     | 1     | 133-8916     | Film     |
Parts in a 112-1842 Valve Control     | |||
Item     | Quantity     | Part Number     | Description     |
1     | 1     | 136-7440     | Shim     |
2     | 1     | 116-3016     | Lever     |
    | 1     | 5V-4410     | Sleeve Bearing     |
3     | 1     | 136-7439     | Spacer     |
4     | 2     | 8T-4815     | Rod End     |
5     | 2     | 8T-4133     | Nut     |
6     | 1     | 116-3018     | Rod     |
7     | 2     | 9R-2806     | Pin     |
8     | 2     | 9R-2807     | Clip     |
9     | 1     | 117-5672     | Boot     |
10     | 1     | 123-3119     | Plate     |
11     | 1     | 8T-9000     | Knob     |
12     | 1     | 101-2788     | Film     |
Installation Procedures for the 106-6373 Valve Control
- Remove the rear console.
Illustration 5 | g00647805 |
(HH) Support plates (1) 106-6374 Support (2) 8T-4195 Bolt (3) 8T-4121 Hard Washer (4) 8T-4133 Nut |
- Locate the support plates (HH) which are surrounding the hydraulic control valve for the backhoe. Refer to Illustration 5.
- Attach the 106-6374 Support (1) to the support plates (HH). Use two 8T-4195 Bolts (2), two 8T-4121 Hard Washers (3), and two 8T-4133 Nuts (4) to secure the support (1) to the support plates (HH). Refer to Illustration 5.
- Insert the 9R-2614 Bearings (6) in the 106-6374 Support (1). Refer to Illustration 6.
Illustration 6 | g00647806 |
(1) 106-6374 Support (3) 8T-4121 Hard Washer (4) 8T-4133 Nut (5) 128-7341 Shaft (6) 9R-2614 Bearing (7) 109-0533 Seal (8) 121-0593 Pedal Assembly (9) 6V-8335 Bolt (10) 8T-4773 Ball Joint (11) 155-6011 Rod (12) 8T-4815 Rod End (13) 9R-2806 Pin (14) 9R-2807 Clip (15) 6V-7744 Locknut |
- Insert the 128-7341 Shaft (5) through the 106-6374 Support (1) and 9R-2614 Bearings (6). Refer to Illustration 6.
- Slide the 109-0533 Seal (7) over the shaft (5). Refer to Illustration 6.
- Attach the 121-0593 Pedal Assembly (8) to the shaft (5). Use a 6V-8335 Bolt (9) and 8T-4121 Hard Washer to secure the pedal assembly to the shaft. Refer to Illustration 6.
- Assemble the following parts according to Illustration 7: two 8T-4133 Nuts (4), 8T-4773 Ball Joint (10), 155-6011 Rod (11) and 8T-4815 Rod End (12) .
The final assembly must measure 133 ± 2 mm (5.24 ± 0.08 inch). Refer to Illustration 7.
Illustration 7 | g00647807 |
(4) 8T-4133 Nut (10) 8T-4773 Ball Joint (11) 155-6011 Rod (12) 8T-4815 Rod End |
- Attach the 8T-4773 Ball Joint (10) to the 128-7341 Shaft (5). Use a 6V-7744 Locknut and a 8T-4121 Hard Washer (3) to secure the ball joint to the shaft. Refer to Illustration 6.
- Attach the 8T-4815 Rod End (12) to the hydraulic control valve (JJ). Use a 9R-2806 Pin (13) and a 9R-2807 Clip (14) to secure the rod end to the hydraulic control valve. Refer to Illustration 8.
Illustration 8 | g00647808 |
(JJ) Hydraulic control valve (12) 8T-4815 Rod End (13) 9R-2806 Pin (14) 9R-2807 Clip |
- Cut a hole which has a diameter of 60 ± 3 mm (2.40 ± 0.12 inch) through the right side of the rear console. Cut a slot from the bottom of the rear console to the hole. The slot must measure 2 ± 1 mm (0.08 ± 0.04 inch) wide. The hole and the slot will allow the rear console to be installed over the shaft (5). Refer to Illustration 9.
Illustration 9 | g00647809 |
(C) Rear console (16) 133-8916 Film |
- Place the 133-8916 Film (16) on the right side of the rear console. Refer to Illustration 9.
- Adjust the rotational position of the pedal assembly. When the pedal is fully actuated, the pedal assembly must stop 15 ± 10 mm (0.60 ± 0.40 inch) away from the floormat.
- Install the rear console when all adjustments are finished.
Installing a 112-1842 Valve Control
- Remove the rear console (C). The knobs (LL) must be removed in order to remove the plate (MM) and the boots (NN). Discard the plate. Refer to Illustration 10.
Illustration 10 | g00648798 |
(C) Rear console (LL) Knobs (MM) Plate (NN) Boots (PP) Shaft (QQ) Retaining ring (RR) Spacer (SS) Support |
- Loosen the shaft (PP) by removing the retaining ring (QQ). Keep the retaining ring. Refer to Illustration 10.
- Remove the shaft from the support (SS). Refer to Illustration 10.
- Remove the spacer (RR). Refer to Illustration 10.
- Slide a 136-7440 Shim (1) on the shaft (PP). More than one shim may be required in order to obtain minimum free play and equal spacing between the levers. Refer to Illustration 11.
Illustration 11 | g00648804 |
(PP) Shaft (QQ) Retaining ring (TT) Main hydraulic control (1) 136-7440 Shim (2) 116-3016 Lever (3) 136-7439 Spacer (4) 8T-4815 Rod End (5) 8T-4133 Nut (6) 116-3018 Rod (7) 9R-2806 Pin (8) 9R-2807 Clip |
- Slide the 116-3016 Lever (2) on the shaft (PP). The 5V-4410 Sleeve Bearing must be installed with the lever (2). The sleeve bearing is part of the lever (2). Refer to Illustration 11.
- Slide a 136-7439 Spacer (3) on the shaft (PP). More than one shim may be required in order to obtain minimum free play and equal spacing between the levers. Refer to Illustration 11.
- Secure the shaft (PP) to the support (SS). Use the retaining ring (QQ) which was removed in Step 2 to secure the shaft to the support.
- Attach two 8T-4815 Rod Ends (4) to the 116-3018 Rod (6). Use two 8T-4133 Nuts (5) in order to attach the rod ends to the rod. Tighten the nuts to a torque of 25 ± 5 N·m (18.44 ± 3.70 lb ft). Refer to Illustration 11.
- Attach the bottom rod end (4) to the main hydraulic control for backhoe operation (TT). Use a 9R-2806 Pin (7) and a 9R-2807 Clip to secure the rod end to the hydraulic control valve. Refer to Illustration 11.
- Attach the top rod end (4) to the lever (2) with a 9R-2806 Pin (7) and a 9R-2807 Clip . Refer to Illustration 11.
- Adjust the length of rod (6) so the longest straight portion of lever (2) is perpendicular to the cab floor.
- Install the 117-5672 Boot (9) over the lever (2). Install the boots (NN) which were removed in Step 1. Refer to Illustration 12.
Illustration 12 | g00648806 |
(NN) Boots (9) 117-5672 Boot (10) 123-3119 Plate (11) 8T-9000 Knob (12) 101-2788 Film |
- Install the 123-3119 Plate (10) over the boots. Refer to Illustration 12.
- Install the 8T-9000 Knob (11) to the lever (2). Also install the knobs (LL) which were removed in Step 1. Refer to Illustration 12.
- Apply the 101-2788 Film (12) to the rear console. Refer to Illustration 12.
Note: Use the 101-2788 Film only when the backhoe loader is equipped with an extendable stick.
Installation of the Hydraulic Lines
Required Parts
Required Parts in the 135-7196 Auxiliary Lines Kit     | |||
Item     | Quantity     | Part Number     | Description     |
1     | 1     | 106-0425     | Plate     |
2     | 1     | 109-2953     | Connector     |
3     | 3     | 7M-8485     | O-Ring Seal     |
4     | 11     | 5K-9090     | O-Ring Seal     |
5     | 2     | 6V-9854     | Swivel Elbow     |
6     | 1     | 123-3201     | Tube     |
7     | 5     | 6V-9746     | O-Ring Seal     |
8     | 1     | 6V-8714     | Seal Connector     |
9     | 2     | 3D-2824     | O-Ring Seal     |
10     | 1     | 124-7633     | Tube     |
11     | 1     | 9S-4183     | Plug     |
12     | 1     | 159-1551     | Hose Assembly     |
13     | 1     | 106-0405     | Hose Assembly     |
14     | 1     | 8T-1889     | Clip     |
15     | 1     | 8T-1890     | Clip     |
16     | 5     | 8T-4121     | Washer     |
17     | 5     | 8T-4137     | Bolt     |
18     | 1     | 8T-1891     | Clip     |
19     | 1     | 8T-1892     | Clip     |
20     | 1     | 106-0416     | Block     |
21     | 1     | 106-0415     | Block     |
22     | 1     | 106-0414     | Block     |
23     | 2     | 7X-2538     | Bolt     |
24     | 2     | 6V-9189     | Locknut     |
25     | 68 cm (27.0 inch)     |
160-2247     | Abrasion Sleeve     |
26     | 2     | 096-0061     | Cable Strap     |
27     | 2     | 106-0411     | Block     |
28     | 2     | 106-0412     | Block     |
29     | 2     | 106-0413     | Block     |
30     | 2     | 6V-9172     | Nut     |
31     | 2     | 2P-1293     | Bulkhead Locknut     |
32     | 1     | 3E-7443     | Union Tee     |
33     | 1     | 6V-9832     | Cap Assembly     |
34     | 1     | 110-7709     | Tube     |
35     | 1     | 3E-7426     | Elbow     |
36     | 2     | 6V-8400     | O-Ring Seal     |
37     | 1     | 6V-9855     | Elbow     |
38     | 1     | 110-7710     | Tube     |
39     | 1     | 8W-5149     | Hose Assembly     |
40     | 1     | 106-0409     | Hose Assembly     |
41     | 1     | 7S-3916     | Clip     |
42     | 1     | 7S-3919     | Clip     |
43     | 2     | 8T-4192     | Bolt     |
44     | 4     | 8T-4223     | Hard Washer     |
45     | 1     | 8S-0023     | Clip     |
46     | 1     | 8S-0024     | Clip     |
47     | 2     | 8T-4139     | Bolt     |
48     | 1     | 5P-8112     | Grommet     |
49     | 1     | 5P-7467     | Clip     |
50     | 1     | 5P-7466     | Clip     |
51     | 1     | 5P-7468     | Clip     |
52     | 1     | 5P-7469     | Clip     |
53     | 1     | 5P-8444     | Grommet     |
54     | 1     | 109-1260     | Bracket     |
55     | 4     | 8T-4136     | Bolt     |
56     | 1     | 108-3872     | Connector     |
57     | 2     | 123-7637     | Cap     |
58     | 2     | 101-0863     | Film     |
59     | 1     | 107-6708     | Bracket     |
60     | 1     | 107-6709     | Connector     |
Installation Instructions
- Connect the 109-2953 Connector (2), 7M-8485 O-Ring Seal (3), and a 5K-9090 O-Ring Seal (4) between the oil filter (EE) and the hose (FF). Refer to Illustration 13.
Note: Caterpillar recommends using the 130-6061 Hose Cleaner Group or the 156-0058 Hose Cleaner Group in order to reduce the risk of contamination to the hydraulic system. The hose cleaner groups clean the inside of hydraulic hoses of most contamination. Refer to Tool Operating Manual, NEHS0643-01.
Illustration 13 | g00646446 |
(EE) Hydraulic oil filter (FF) Hose (GG) Control valve (2) 109-2953 Connector (3) 7M-8485 O-Ring Seal (4) 5K-9090 O-Ring Seal (5) 6V-9854 Swivel Elbow (6) 123-3201 Tube (7) 6V-9746 O-Ring Seal (8) 6V-8714 Seal Connector (9) 3D-2824 O-Ring Seal (10) 124-7633 Tube (12) 159-1551 Hose Assembly (13) 106-0405 Hose Assembly (14) 8T-1889 Clip (15) 8T-1890 Clip (16) 8T-4121 Washer (17) 8t-4137 Bolt |
- Connect a 6V-9854 Swivel Elbow (5) and a 5K-9090 O-Ring Seal (4) to the 109-2953 Connector (2). Refer to Illustration 13.
- Connect the 124-7633 Tube (10) and a 5K-9090 O-Ring Seal (4) to the 159-1551 Hose Assembly (12). Refer to Illustration 13.
- Connect the 123-3201 Tube (6), 5K-9090 O-Ring Seal (4), 6V-8714 Seal Connector (8), and 3D-2824 O-Ring Seal (9) to the top port of the seventh control valve (GG). Refer to View V-V and View Y-Y of Illustration 14.
Illustration 14 | g00646451 |
(AA) Support plate (GG) Control valve (4) 5K-9090 O-Ring Seal (6) 123-3201 Tube (7) 6V-9746 O-Ring Seal (8) 6V-8714 Seal Connector (9) 3D-2824 O-Ring Seal (10) 124-7633 Tube (11) 9S-4183 Plug (12) 159-1551 Hose Assembly (13) 106-0405 Hose Assembly (14) 8T-1889 Clip (15) 8T-1890 Clip (16) 8T-4121 Washer (17) 8T-4137 Bolt (18) 8T-1891 Clip (19) 8T-1892 Clip (20) 106-0416 Block (21) 106-0415 Block (22) 106-0414 Block (23) 7X-2538 Bolt (24) 6V-9189 Locknut |
- Install 3D-2824 O-Ring Seal (9) and 9S-4183 Plug (11) in the bottom port of the seventh control valve (GG). Refer to View Y-Y of Illustration 14.
- Connect the 123-3201 Tube (6) and a 6V-9746 O-Ring Seal (7) to the 106-0405 Hose Assembly (13). Refer to Illustrations 13 and 14.
- Use the 8T-4137 Bolt (J) and 8T-4121 Washer (K) from the disassembly procedure to install the 8T-1891 Clip (18) and the 8T-1892 Clip (19). Refer to View Z-Z in Illustrations 13 and 14.
- Support hose (10) and hose (12) by using the following parts: 8T-1889 Clip (14), 8T-1890 Clip (15), 8T-4121 Washer (16) and 8T-4137 Bolt (17). Refer to Illustration 13 and View W-W in Illustration 14.
- Remove the existing blocks and screws in View X-X. Refer to Illustrations 13 and 14.
- Drill out the 8 mm (0.32 inch) threaded holes in the swing casting. Enlarge the holes to 10 mm (0.40 inch). Refer to Illustrations 13 and 14.
- Put hose (12) and hose (13) in the new blocks: 106-0416 Block (20), 106-0415 Block (21) and 106-0414 Block (22). Attach the blocks to the swing casting with two 7X-2538 Bolts (23) and two 6V-9189 Locknuts (24) .
Refer to View X-X in Illustration 14.
- Apply a 68 cm (27.0 inch) length of 160-2247 Abrasion Sleeve (25) to the 159-1551 Hose Assembly (12). Secure the abrasion sleeve to the hose with two 096-0061 Cable Straps (26). Refer to Illustration 15.
Illustration 15 | g00646453 |
(M) Support plate (3) 7M-8485 O-Ring Seal (4) 5K-9090 O-Ring Seal (5) 6V-9854 Swivel Elbow (7) 6V-9746 O-Ring Seal (12) 159-1551 Hose Assembly (13) 106-0405 Hose Assembly (16) 8T-4121 Washer (17) 8T-4137 Bolt (25) 160-2247 Abrasion Sleeve (26) 096-0061 Cable Strap (27) 106-0411 Block (28) 106-0412 Block (29) 106-0413 Block (31) 2P-1293 Bulkhead Locknut (32) 3E-7443 Union Tee (33) 6V-9832 Cap Assembly (34) 110-7709 Tube (39) 8W-5149 Hose Assembly (41) 7S-3916 Clip (42) 7S-3919 Clip (43) 8T-4192 Bolt (44) 8T-4223 Hard Washer (47) 8T-4139 Bolt (48) 5P-8112 Grommet (49) 5P-7467 Clip (50) 5P-7466 Clip (54) 109-1260 Bracket (55) 8T-4136 Bolt (56) 108-3872 Connector (57) 123-7637 Cap |
- Route the hydraulic hoses which are on top of the boom through the two sets of 106-0411 Blocks (27), 106-0412 Blocks (28), and 106-0413 Blocks (29). Refer to Illustration 15.
- Attach each set of assembled blocks (27), (28), and (29) to the boom. Install each set of blocks with two 8T-4137 Bolts (17). Refer to Illustration 15.
- Connect 106-0405 Hose Assembly (13) and a 6V-9746 O-Ring Seal (7) to the 3E-7443 Union Tee (32). Use a 2P-1293 Bulkhead Locknut (31) to secure the connection of the hose (13) and union tee (32) to the support plate (M). Refer to Illustration 15.
- Connect the 3E-7443 Union Tee (32) and a 5K-9090 O-Ring Seal (4) to the 6V-9854 Swivel Elbow (5). Refer to Illustration 15.
- Close off one end of the union tee (32) with a 6V-9832 Cap Assembly (33). Refer to Illustration 15.
- Connect the 6V-9854 Swivel Elbow (5) and a 6V-9746 O-Ring Seal (7) to the 110-7709 Tube (34). Refer to Illustration 15.
- Connect the tube (34) to the 8W-5149 Hose Assembly (39). Refer to Illustration 15.
- Secure the tube (34) and the hose (39) to the right side of the boom with the following parts: 7S-3916 Clip (41), 7S-3919 Clip (42), 8T-4192 Bolt (43) and 8T-4223 Hard Washer (44). Refer to Illustration 15.
- Secure the end of the hose (39) to the stick by using the following parts: 7M-8485 O-Ring Seal (3), 6V-9746 O-Ring Seal (7), 8T-4121 Washer (16), 2P-1293 Bulkhead Locknut (31), 109-1260 Bracket (54), 8T-4136 Bolt (55) and 108-3872 Connector (56). Refer to Illustration 15.
Tighten the bulkhead locknut (31) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).
- Protect against contamination by capping hose (39) with a 123-7637 Cap (57). Refer to Illustration 15.
Tighten the cap (57) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).
- Support the hose (39) by attaching the hose to the stick with the following parts: 8T-4223 Hard Washer (44), 8T-4139 Bolt (47), 5P-8112 Grommet (48), 5P-7467 Clip (49) and 5P-7466 Clip (50). Refer to Illustration 15.
- Connect 159-1551 Hose Assembly (12) and 5K-9090 O-Ring Seal (4) to the 3E-7426 Elbow (35) with the 6V-9172 Nut (30). The hose (12) and elbow (35) is secured to the support plate (M) with the nut (30). Refer to Illustration 16.
Illustration 16 | g00646462 |
(M) Support plate (3) 7M-8485 O-Ring Seal (4) 5K-9090 O-Ring Seal (12) 159-1551 Hose Assembly (16) 8T-4121 Washer (30) 6V-9172 Nut (35) 3E-7426 Elbow (36) 6V-8400 O-Ring Seal (37) 6V-9855 Elbow (38) 110-7710 Tube (40) 106-0409 Hose Assembly (43) 8T-4192 Bolt (44) 8T-4223 Hard Washer (45) 8S-0023 Clip (46) 8S-0024 Clip (47) 8T-4139 Bolt (51) 5P-7468 Clip (52) 5P-7469 Clip (53) 5P-8444 Grommet (55) 8T-4136 Bolt (56) 108-3872 Connector (57) 123-7637 Cap (58) 101-0863 Film (59) 107-6708 Bracket (60) 107-6709 Connector |
- Connect the 3E-7426 Elbow (35) and a 6V-8400 O-Ring Seal (36) to the 6V-9855 Elbow (37). Refer to Illustration 16.
- Connect the 6V-9855 Elbow (37) and a 6V-8400 O-Ring Seal (36) to the 110-7710 Tube (38). Refer to Illustration 16.
- Connect the 110-7710 Tube (38) and a 5K-9090 O-Ring Seal (4) to the 106-0409 Hose Assembly (40). Refer to Illustration 16.
- Secure hoses (38) and (40) to the boom with the following parts: 8T-4192 Bolt (43), 8T-4223 Hard Washer (44), 8S-0023 Clip (45) and 8S-0024 Clip (46). Refer to Illustration 16.
- Secure the 106-0409 Hose Assembly (40) to the stick with the following parts: 8T-4223 Hard Washer (44), 8T-4139 Bolt (47), 5P-7468 Clip (51), 5P-7469 Clip (52) and 5P-8444 Grommet (53). Refer to Illustration 16.
- Secure the end of hose (40) to the stick with the following parts: 7M-8485 O-Ring Seal (3), 5K-9090 O-Ring Seal (4), 8T-4121 Washer (16), 6V-9172 Nut (30), 8T-4136 Bolt (55), 107-6708 Bracket (59) and 107-6709 Connector (60).
Tighten the nut (30) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft).
Refer to Illustration 16.
- Protect against contamination by capping hose (40) with a 123-7637 Cap (57). Tighten the cap (40) to a torque of 150 ± 10 N·m (111 ± 7.4 lb ft). Refer to Illustration 16.
- Apply a 101-0863 Film (58) to the right side of the stick. The film must indicate the flow of the hydraulic oil to the hydraulic work tools. Place the film 329 mm (13 inch) from the cap (57) on the end of hose (39). Refer to Illustration 18.
Illustration 17 | g00654368 |
(CC) View of the stick from the left side of the machine (DD) View of the stick from the right side of the machine |
Illustration 18 | g00646464 |
(CC) View of the stick from the left side of the machine (DD) View of the stick from the right side of the machine (39) 8W-5149 Hose Assembly (40) 106-0409 Hose Assembly (57) 123-7637 Cap (58) 101-0863 Film |
- Apply a 101-0863 Film (58) to the left side of the stick. The film must indicate the flow of the hydraulic oil from the hydraulic work tools. Place the film 329 mm (13 inch) from the cap (57) on the end of hose (40). Refer to Illustration 18.
- Install the floorplate in the cab.
- Install the rear console cover.
- Test the hydraulic system according to the ""Testing the Hydraulic System" " section in this publication.
Testing the Hydraulic System
- Tighten all of the new hose connections.
- If you have not installed either a 106-6373 Valve Control or a 112-1842 Valve Control , see the section ""Installing a Valve Control" " before you proceed with the testing procedures.
- Fill the hydraulic system oil tank according to the Operation and Maintenance Manual for your machine.
- Test and adjust the hydraulic system. Refer to the Test and Adjusting manual for your machine.
Personal injury or death can result from improperly checking for a leak. Always use a board or cardboard when checking for a leak. Escaping air or fluid under pressure, even a pin-hole size leak, can penetrate body tissue causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. |
- Secure the floorplate and secure the floormat in the cab when all repairs are finished.
Welding the 106-0425 Plate to the Boom
Welding Requirements
Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of LaborWashington, D.C. 20210 |
Welding quality is critical to the success of the reinforcement procedures. Welds must be smooth and continuous. No undercutting is allowed. No overlap is allowed. Grind the ends of the welds to a smooth radius.
Prepare the metal for welding according to ""Welding the Reinforcement Plate to the Boom" ". Refer to the illustrations in this special instruction for welding symbols and specifications.
Use a 1U-5236 Welding Rod or an equivalent electrode to weld the reinforcement plate to the boom. Basic welding wire ESAB OK tubrod 15.00 with a 1.2 mm (0.05 inch) diameter can also be used. The basic welding wire must be the equivalent to AWS A5.20 E71T-1 with positive polarity. The welding wire must be protected with CO2 gas.
All electrodes must be completely dried. The electrodes can be dried by heating the electrodes to 300 °C (572 °F). The electrodes must be dried for at least 30 minutes.
Do not weld in windy conditions. Do not weld when temperatures are below 16 °C (61 °F).
Penetration characteristics may vary greatly depending on the electrode diameter, shielding gas, welding current, and plate thickness. Geometry of the welded joints, surface conditions, and composition of the base metal and electrode also affect the welds.
For more welding information, consult the Caterpillar Service Welding Guide, SEBD0512.
Welding Procedures
- Disconnect the battery from the electrical system.
Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas. |
NOTICE |
---|
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components. |
Illustration 19 | g00642374 |
Weld the 106-0425 Plate (1) to this position on the boom (R) . |
Illustration 20 | g00642488 |
Prepare the shaded area for welding. |
- Cover the boom and surrounding components in order to protect the parts from welding spatters and paint spatters.
- Remove all paint, rust, dirt, and scale from the metal. The material can be removed by using a wire brush or by buffing or grinding. Refer to Illustrations 19 and 20.
- Remove any oil or grease with an approved solvent.
- Position the plate on the boom. Jacks and other supports can be used to hold the plate in place while the welding procedures are being conducted.
- Weld the plate (1) to the boom (R) by using a 1U-5236 Welding Rod . Weld from point (T) to point (U) in one continuous weld. Refer to Illustration 21 for more information.
Illustration 21 | g00642497 |
Weld the plate (1) to the boom (R). Weld around the plate from point (T) to point (U) . |
- Grind the ends of the welds to a smooth finish.
- Shot blast all the welded areas.
- Paint the weld, the boom, and the plate. Use an authorized Caterpillar paint.
- Remove all protective covers from the boom.